Absorbent article having a nonwoven and apertured film coversheet

ABSTRACT

An absorbent article having improved strikethrough, rewet characteristics, and feel is disclosed. The absorbent article has a topsheet comprising a nonwoven material and apertured thermoplastic film. The apertured thermoplastic film is treated with a surfactant preferably by incorporating the surfactant into the resin used to make the thermoplastic film. The combination of the nonwoven material and the surfactant-treated apertured thermoplastic film permit liquids to rapidly penetrate the topsheet while preventing liquid in the absorbent core of the article from flowing back through the topsheet. The nonwoven material provides the topsheet with improved, less plastic-like feel.

This is a continuation of application Ser. No. 08/322,910, filed on Oct.13, 1994, which is a division of application Ser. No. 08/072,660, filedon Jun. 4, 1993, which is a continuation of application Ser. No.07/794,745, filed on Nov. 9, 1991 all now abandoned.

FIELD OF THE INVENTION

This invention relates to absorbent articles such as diapers,incontinent articles, sanitary napkins, and the like. More particularly,this invention relates to absorbent articles having a nonwoven andapertured film coversheet.

BACKGROUND OF THE INVENTION

All manner and variety of absorbent articles configured for theabsorption of body fluids are, of course, well known. Current types ofabsorbent articles include diapers, incontinent articles, and sanitarynapkins.

A major in use problem encountered with known absorbent articles isleakage of waste product which contaminates clothing articles thatcontact the absorbent article, such as pants, shirts, and bedding. Theamount of leakage experienced by the wearer can be reduced by improvingthe rate at which the liquid enters the absorbent core. Thus, anabsorbent article in which the liquid rapidly penetrates the topsheetand is contained in the absorbent core will experience less leakage thanan absorbent article in which liquid is able to run across the topsheetbefore penetrating into the absorbent core. Reducing run-off, therefore,reduces the amount of leakage experienced with the absorbent article.

Another in-use problem associated with absorbent articles is the drynessof the skin contacting surface. Generally, the drier the skin contactingsurface, the more comfortable the absorbent article. There have beenseveral patents directed towards reducing the surface wetness indisposable diaper structures. U.S. Pat. No. 3,945,386 issued toAnczurowski on Mar. 23, 1976 and U.S. Pat. Nos. 3,965,906 and 3,994,299issued to Karami on Jun. 29, 1976 and Nov. 30, 1976, respectively, teachdiaper structures having a perforated thermoplastic film interposedbetween the topsheet and the absorbent core. U.S. Pat. No. 4,324,247issued to Aziz on Apr. 13, 1982 describes an effort directed to bothreducing run-off and reducing the surface wetness of absorbent articles.

Still another problem associated with absorbent articles is the feel ofthe skin contacting surface. A problem with utilizing formed films isthat some consumers do not like the plastic feel associated with suchfilms. A number of efforts have been directed at improving the feel ofthe surface of absorbent articles. One effort is described in U.S. Pat.No. 3,967,623 issued to Butterworth, et al. The Butterworth patent isdirected to an absorbent pad having a facing sheet comprising aperforated thermoplastic web having an integral fibrous or sueded outersurface.

The products described in most of the above references, however, areless than ideal in achieving a good combination of all three desiredproperties of reduced surface run-off, improved rewet characteristics,and improved feel. While the product described in the Aziz patent worksquite well, the search for improved coversheets has continued.

It is therefore an object of the present invention to provide anabsorbent article having a good combination of reduced surface run-offcharacteristics, improved surface dryness, and an improved softer, lessplastic-like feel.

Other objects of the present invention will become more fully apparentin the following description of the embodiments of this invention andfrom the appended claims.

SUMMARY OF THE INVENTION

This invention relates to absorbent articles such as diapers,incontinent articles, sanitary napkins, and the like. More particularly,this invention relates to absorbent articles having a nonwoven andapertured film coversheet.

The absorbent article comprises, in its basic form, a liquid perviouscoversheet (or topsheet), a liquid impervious backsheet joined to thetopsheet, and an absorbent core positioned between the topsheet andbacksheet. The topsheet is comprised of a nonwoven material, preferablya nonwoven fabric, and an apertured plastic film. The apertured plasticfilm preferably has a multiplicity of tapered capillaries. Thecapillaries enable the film to transport liquid through the topsheet tothe absorbent core and prevent liquid from flowing in the reversedirection. At least the film, and preferably both the nonwoven fabricand the film, are treated with a surfactant to enhance the permeabilitycompletely through the topsheet.

The resulting absorbent article is believed to exhibit a goodcombination of all three desired characteristics of reduced surfacerun-off and improved surface dryness characteristics, as well asimproved feel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a simplified perspective view of an absorbent article of thepresent invention.

FIG. 2 is a cross-sectional view taken along line 2--2 of FIG. 1.

FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 1.

FIG. 4 is an edge view of the nonwoven fabric comprising part of thetopsheet of the absorbent article.

FIG. 5 is an edge view of the apertured plastic film comprising theother component of the topsheet.

FIGS. 6-8 are edge views of alternative embodiments of the completelyassembled topsheet.

FIG. 9 is a schematic representation of one process for making acoversheet for the absorbent article.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

1. The Absorbent Article.

This invention relates to absorbent articles such as diapers,incontinent articles, sanitary napkins, and the like. More particularly,this invention relates to absorbent articles having a nonwoven andapertured film coversheet.

The term "absorbent article", as used herein, refers to articles whichabsorb and contain body exudates. More specifically, the term refers toarticles which are placed against or in proximity to the body of thewearer to absorb and contain the various exudates discharged from thebody. The term "absorbent article" is intended to include diapers,incontinent articles, sanitary napkins, pantiliners, and other articlesused to absorb body exudates. The term "disposable" refers to articleswhich are intended to be discarded after a single use and preferablyrecycled, composted, or otherwise disposed of in an environmentallycompatible manner. (That is, they are not intended to be laundered orotherwise restored or reused as an absorbent article.)

The term "diaper" refers to a garment generally worn by infants andincontinent persons which is drawn up between the legs and fastenedabout the waist of the wearer. Suitable diapers that can be providedwith the coversheet described herein are disclosed in U.S. Pat. Re. No.26,152, issued to Duncan, et al. on Jan. 31, 1967; U.S. Pat. No.3,860,003 issued to Buell on Jan. 14, 1975; U.S. Pat. No. 4,610,678issued to Weisman, et al. on Sep. 9, 1986; U.S. Pat. No. 4,673,402issued to Weisman, et al. on Jun. 16, 1987; U.S. Pat. No. 4,695,278issued to Lawson on Sep. 22, 1987; U.S. Pat. No. 4,704,115 issued toBuell on Nov. 3, 1987; U.S. Pat. No. 4,834,735 issued to Alemany, et al.on May 30, 1989; U.S. Pat. No. 4,888,231 issued to Angstadt on Dec. 19,1989; and U.S. Pat. No. 4,909,803issued to Aziz, et al. on Mar. 20,1990.

The term "incontinent article" refers to pads, undergarments (pads heldin place by a suspension system of same type, such as a belt, or thelike), inserts for absorbent articles, capacity boosters for absorbentarticles, briefs, bed pads, and the like, regardless of whether they areworn by adults or other incontinent persons. Suitable incontinentarticles that can be provided with the coversheet described herein aredisclosed in U.S.Pat. No. 4,253,461 issued to Strickland, et al. on Mar.3, 1981; U.S. Pat. Nos. 4,597,760 and 4,597,761 issued to Buell; theabove-mentioned U.S. Pat. Nos. 4,704,115; 4,909,802 issued to Ahr, etal.; U.S. Pat. No. 4,964,860 issued to Gipson, et al. on Oct. 23, 1990;and in U.S. Pat. Application Ser. Nos. 07/637,090 and 07/637,571 filedrespectively by Noel, et al. and Feist, et al. on Jan. 3, 1991.

The term "sanitary napkin" refers to an article which is worn by femalesadjacent to the pudendal region that is intended to absorb and containvarious exudates which are discharged from the body (e.g., blood,menses, and urine). Suitable sanitary napkins that can be provided withthe coversheet described herein are disclosed in U.S. Pat. No.4,285,343, issued to McNair on Aug. 25, 1981; U.S. Pat. Nos. 4,589,876and 4,687,478,issued to Van Tilburg on May 20, 1986 and Aug. 18, 1987respectively; U.S. Pat. Nos. 4,917,697 and 5,007,906 issued to Osborn,et al. on Apr. 17, 1990 and Apr. 16, 1991, respectively; and U.S. Pat.Nos. 4,950,264 , and 5,009,653 issued to Osborn on Aug. 21, 1990 andApr. 23, 1991, respectively; and in U.S. Pat. Application Ser. No.07/605,583 filed Oct. 29, 1990 in the name of Visscher, et al.

The term "pantiliner" refers to absorbent articles that are less bulkythansanitary napkins which are generally worn by women between theirmenstrual periods. Suitable pantiliners that can be provided with thecoversheet described herein are disclosed in U.S. Pat. No. 4,738,676entitled "Pantiliner" issued to Osborn on Apr. 19, 1988.

The disclosures of all patents, patent applications (and any patentswhich issue thereon, as well as any corresponding published foreignpatent applications), and publications mentioned throughout this patentapplication are hereby incorporated by reference herein. It is expresslynot admitted, however, that any of the documents incorporated byreferenceherein teach or disclose the present invention. It is alsoexpressly not admitted that any of the commercially available materialsor products described herein teach or disclose the present invention.

FIG. 1 shows a simplified absorbent article 10 that could represent adiaper prior to its being placed on a wearer. It should be understood,however, that the present invention is not limited to the particulartype or configuration of absorbent article shown in the drawings. Asshown in FIG. 2, such an absorbent article 10 basically comprisestopsheet 12, backsheet 14, and absorbent core 16.

The absorbent article 10 has two surfaces, a body-contacting surface (or"body surface") 10a and a garment surface lob. The body surface 10a isintended to be worn adjacent to the body of the wearer. The garmentsurface lob of the absorbent article 10 (shown in FIG. 2) is on theopposite side and is intended to be placed adjacent to the wearer'sundergarments or clothing when the absorbent article 10 is worn.

The absorbent article 10 has two centerlines, a longitudinal centerline1 and a transverse centerline t. The terms "longitudinal" and"transverse" or "lateral" (the latter two being interchangeable), aredefined in U.S. Pat. No. 5,007,906 issued to Osborn, III, et al. and areapplicable to theabsorbent articles described herein. FIG. 1 shows thatthe absorbent article 10 has two spaced apart longitudinal edges 18 andtwo spaced aparttransverse or end edges (or "ends") 20, which togetherform the periphery 22 of the absorbent article 10.

The individual components of the absorbent article 10 will now be lookedatin greater detail.

The topsheet 12 is compliant, soft-feeling and non-irritating to thewearer's skin. Further, topsheet 12 is liquid permeable, permittingliquids to readily penetrate through its thickness. The topsheet 12 hasa body-facing side or face 12a and a garment-facing side or face 12b,two longitudinal or side edges 12c and two end edges 12d. (A similarnumberingsystem will be used for the other components of the diaper 10.That is, theside of the component facing the wearer's body will bedesignated by the number of the component and a reference letter "a",the side facing the wearer's undergarments by the number of thecomponent and the letter "b", and the side and end edges by the numberof the component and the reference letters "c" and "d" respectively.)

The topsheet 12 comprises two components, a nonwoven material,preferably in the form of a fabric 24, and a three dimensional aperturedplastic film26. The garment-facing side or face 24b of the nonwovenfabric 24 is preferably maintained in close contact with, and morepreferably bonded to, the body-facing face 26a of the apertured plasticfilm 26. The component parts of the topsheet 12 are examined in greaterdetail below.

The nonwoven fabric 24 may be any nonwoven fabric that is permeable toliquids. A suitable nonwoven fabric 24 may be manufactured from a widerange of materials such as natural fibers (e.g., wood or cotton fibers),synthetic fibers (e.g., polyester, polypropylene) or a combinationthereof. The nonwoven fabric 24 is preferably made from fibers selectedfrom a group consisting of polypropylene, polyester, polyethylene,polyvinylalcohol, starch base resins, polyurethanes, cellulose andcellulose esters.

Clearly, there are a number of manufacturing techniques which may beutilized to manufacture the nonwoven fabric 24. For example, nonwovenfabric 24 may be resin-bonded, needle punched, spunbonded, carded, thelatter including, thermally bonded, air-thru bonded, and spunlacedfabrics. A preferred nonwoven fabric 24 is a thermally bondedpolypropylene fabric.

The nonwoven fabric 24 should be lightweight having a weight from about1 to about 40 g/sq m, preferably from about 1 to about 23 g/sq.m. Forone embodiment, the nonwoven fabric 24 has a basis weight range of fromabout 18 to about 22 grams per square yard (about 21 to about 26g/sq.m.) and a caliper C as shown in FIG. 4, of from about 5 to about 15mils (about 0.13to about 0.38 mm.) when measured under a load of about200 pascals. Such a nonwoven fabric 24 is further characterized by aminimum wet or dry tensile strength of at least about 400 grams percentimeter in the longitudinal or machine direction and at least about55 grams per centimeter in the cross machine direction.

In another embodiment, the nonwoven fabric 24 has a lighter weight offrom about 8 to about 12 g/sq m. Such lighter nonwoven fabrics arehighly preferred. They are preferred because they can be used (with alightweightfilm) to form a composite topsheet 12 that is sufficientlythin and lightweight that it behaves as a single sheet of material. Thisprovides the advantages that such a topsheet may be more flexible anduse smaller amounts of raw materials.

The nonwoven fabric 24 preferably has a pattern of thermal bond sites34. One preferred nonwoven fabric comprises a carded thermally dotbonded polypropylene web. The thermal bonds in such a fabric arepreferably rectangularly-shaped in plan view. The bonds are preferablyarranged in staggered rows. Another preferred nonwoven is a spunbondedpolypropylene web with similarly arranged thermal bonds. Still anotherpreferred nonwoven fabric 24 is a carded polypropylene web which isembossed in accordance with the method described in U.S. Pat. No.4,781,710 issued to Megison, et al. This nonwoven fabric 24 has embossedand thermal bonded areas that are diamond-shaped in plan view. Thediamond-shaped bonds are spaced apart and arranged in a diamond-shapedgrid such as is shown in FIGS. 1 and 2 of the Megison, et al. patent.(The embossing need not extend into the underlying core, however.)

The apertured plastic film 26 is preferably located between the nonwovenfabric 24 and the absorbent core 16. As shown in FIG. 5, the aperturedplastic film 26 is preferably a three-dimensional structure which has aplurality of tapered capillaries 40, each of which has a base opening38, and an apex opening 42. The apex openings 42 are preferably inintimate contact with the absorbent core 16.

The apertured plastic film 26 is manufactured from a liquid impervious,preferably thermoplastic material. One suitable material is a lowdensity polyethylene film having a thickness of from 0.001 to 0.002inches (0.0025to 0.0051 cm.). The thermoplastic material for use in themanufacture of the apertured plastic film 26 is selected from a groupconsisting generally of polyethylene, polypropylene, polyvinyl chloride,starch base resins, polyvinylalcohol, polyurethanes, polycaprolactoneand cellulose esters. The thermoplastic material used in the presentinvention preferably has a density in the range of from about 0.90 g/cm³to about 1.20 g/cm³, with the more preferred range of densities beingfrom about 0.91 g/cm³ to about 0.92 g/cm³. The general melt indicesrange for such material is preferably from about 2 to about 100, withthe more preferred range being from about 4 to about 25.

In one preferred embodiment, the thermoplastic material is provided witha multiplicity of tapered capillaries 40 in a manner, size,configuration, and orientation set forth in U.S. Pat. No. 3,939,135issued to Thompson onDec. 30, 1975. Other suitable apertured plasticfilms are disclosed in U.S.Pat. No. 4,324,426, issued to Mullane, et al.on Apr. 13, 1982, U.S. Pat. No. 4,342,314, issued to Radel, et al. onAug. 3, 1982, and U.S. Pat. No. 4,463,045, issued to Ahr, et al. on Jul.31, 1984. The apertured plastic film 26 can comprise other types ofapertured plastic films that are not thermoplastic. The type of filmused depends on the type of processing thefilm and nonwoven componentsare subjected to during the manufacture of thetopsheet 12. Thermoplasticfilms are used when the nonwoven fabric 24 and the film 26 areintegrally formed into a composite structure by melting. Other suitabletypes of apertured films include, but are not limited to hydro-formedfilms. Hydro-formed films are described in at least some of thefollowing U.S. Pat. Nos.: 4,609,518, 4,629,643, 4,695,422, 4,772,444,4,778,644, and 4,839,216 issued to Curro, et al., and U.S. Pat. No.4,637,819 issued to Ouellette, et al.

The nonwoven fabric 24 and the apertured plastic film 26 may be placedintoa face-to-face relationship. The two components may be secured orunsecured. The two components, if secured, may be secured to each otherbymany different methods (or securement means) or combinations ofmethods. Suitable methods for securing the two components include, butare not limited to adhesives, fusion including heat bonding and/orpressure bonding, ultrasonics, and dynamic mechanical bonding.

The adhesives can be applied in a uniform continuous layer, a patternedlayer, or an array of separate lines, spirals, beads, or spots ofadhesive. The adhesive attachment preferably comprises an open patternnetwork of filaments of adhesive as is disclosed in U.S. Pat. No.4,573,986 issued to Minetola, et al. on Mar. 4, 1986, or an open patternnetwork of filaments comprising several lines of adhesive filamentsswirled into a spiral pattern as illustrated by the apparatus and methodshown in U.S. Pat. No. 3,911,173 issued to Sprague, Jr. on Oct. 7, 1975;U.S. Pat. No. 4,785,996 issued to Zieker, et al. on Nov. 22, 1978; andU.S. Pat. No. 4,842,666 issued to Werenicz on Jun. 27, 1989. A method ofheat/pressure bonding that could be used is described in U.S. Pat. No.4,854,984 issued to Ball, et al. on Aug. 8, 1989.

The nonwoven, fabric 24 and the apertured plastic film 26 mayalternativelybe indirectly secured. For instance, the two componentscould be secured toor through a thin layer of airfelt, or a layer-ofhydrophobic material positioned between the nonwoven fabric 24 and theapertured plastic film 26. Preferably, such additional layer or layersare treated with a surfactant (as described in greater detail below).

The nonwoven fabric 24 and the apertured plastic film 26 canalternatively be integrally formed into a composite structure. The terms"composite" "composite structure" or "combination", as used herein,refer to relationships in which portions of the nonwoven fabric 24extend into the film 26, and vice versa so that they are integrallyattached. These components cease to exist as separate layers in aface-to-face relationship.

FIGS. 6 and 7 show several possible embodiments of such a compositestructure. In the embodiments shown, at least a portion of the fibers inthe nonwoven web 24 are embedded in some portion of the thermoplasticfilm26. The relationship between the surfaces of the respectivecomponents differs in each embodiment. However, in both embodimentsshown in FIGS. 6 and 7, the garment-facing face 24b of the nonwovenmaterial 24 is positioned between the body-facing and garment-facingsurfaces of the apertured film 26. These can be contrasted with theembodiment shown in FIG. 8 in which the components are separate layersin a face-to-face relationship.

FIG. 6 shows an example of a composite structure in which thebody-facing sides of the two components, 24a and 26a, lie inapproximately the same plane. FIG. 7 shows a composite structure inwhich the body-facing side 24a of the nonwoven material 24 is above thatof the film 26 so the body-facing side 26a of the film 26 is positionedbetween the surfaces of the nonwoven fabric 24. The embodiment shown inFIG. 7 is believed to be the more preferable of these two embodimentsbecause it provides the softer nonwoven fabric 24 over the entirebody-facing surface 12a of the topsheet 12. This can be contrasted withthe embodiment shown in FIG. 6. In the embodiment shown in FIG. 6,portions of the fibers comprising the nonwoven fabric 24 are embeddedinto the film along at least a portion of the body-facing surface 12a ofthe topsheet 12. These embedded portions are typically not as soft asthe nonwoven material alone.

In other alternative embodiments, the topsheet 12 could be constructedso that the film 26 underlies only a portion of the area of the nonwovenfabric 24. For example, the film 26 may be of a smaller size that itonly covers the portion of the absorbent article into which liquids aredeposited or absorbed. This could be in the crotch region of theabsorbentarticle or in a urine "target zone".

The absorbent core 16 is positioned between the topsheet 12 and thebacksheet 14. The absorbent core 16 provides the means for absorbingbodily exudates. The absorbent core 16 need not have an absorbentcapacitymuch greater than the total amount of exudates to be absorbed.The absorbent core 16 is generally compressible, conformable, andnon-irritating to the user's skin. It can comprise any material used inthe art for such purpose. Examples include comminuted wood pulp which isgenerally referred to as airfelt, creped cellulose wadding, cross-linkedcellulose fibers, absorbent foams, absorbent sponges, synthetic staplefibers, polymeric fibers, hydrogel-forming polymer gelling agents, peatmoss, combinations of the foregoing, or any equivalent material orcombinations of materials.

Suitable cross-linked cellulose fibers are described in U.S. Pat. No.4,888,093, issued Dec. 19, 1989 to Cook, et al.; U.S. Pat. No.4,822,543, issued Apr. 18, 1989 to Dean, et al.; U.S. Pat. No.4,889,595, issued Dec.26, 1989 to Schoggen, et al.; U.S. Pat. No.4,889,596, issued Dec. 26, 1989to Schoggen, et al.; U.S. Pat. No.4,898,642, issued Feb. 6, 1990 to Moore,et al.; and U.S. Pat. No.4,935,022, issued Jun. 19, 1990 to Lash, et al.

The characteristics of the absorbent core 16 for particular types ofabsorbent articles are described in greater detail in the patents anddocuments incorporated by reference herein, and the patents and otherdocuments incorporated by reference in those documents, the disclosuresofwhich are all incorporated by reference herein. Other suitableabsorbent core arrangements are described in U.S. Pat. Nos. 4,988,344and 4,988,345,and European Patent Application Publication No. 0 198 683,published Oct. 22, 1986 in the name of Duenk, et al. which are alsoincorporated by reference herein. The absorbent article 10 could alsoinclude any additional layers or other components such as are describedin the patentsincorporated by reference. For example, the absorbentarticle 10 may comprise an acquisition layer or patch of cross-linkedcellulose fibers positioned between the topsheet 12 and the absorbentcore 16.

The backsheet 14 is impervious to liquids and is preferably manufacturedfrom a thin plastic film, although other flexible liquid imperviousmaterials may also be used. The backsheet 14 prevents liquid containedin absorbent core 16 from wetting articles which contact the absorbentarticle 10. Polyethylene films having a thickness of from about 0.001 toabout 0.002 inches (0.0025 to 0.0051 cm.) have been used for thebacksheet14 with satisfactory results. As used herein, the term"flexible" refers tomaterials which are compliant and which will readilyconform to the generalshape and contours of the human body.

The backsheet 14 is superimposed on the garment-facing side 16b ofabsorbent core 16 and preferably extends beyond the edges thereof. Thetopsheet 12 is superimposed over the body-facing side 16a of theabsorbentcore 16, and may also extend beyond the edges of the core 16.The absorbentcore 16 is, therefore, positioned between the topsheet 12and the backsheet14. The topsheet 12 and backsheet 14 are joined to eachother such as around their peripheries. The topsheet 12 and backsheet 14can be joined in any suitable manner such as by the use of adhesives,crimping, heat-sealing, or ultrasonic bonding. A more detaileddescription of how topsheet 12, backsheet 14, and absorbent core 16 maybe assembled for particular types of absorbent articles is provided inthe documents incorporated by reference herein.

2. Method of Making the Absorbent Article.

A suitable process of preparing the topsheet 12 is shown in FIG. 9. Oneversion of the process described below is also set forth in U.S. Pat.Application Ser. No. (Serial No. not yet assigned) filed in the name ofLowe by Tredegar Film Products on the same day as the presentapplication.

The apparatus for making the topsheet for the absorbent article of thepresent invention is designated 100. The apparatus 100 includes a firstsupply source 102 and a second supply source 104. The supply sources (or"supply means") 102 and 104 feed the materials that will comprise thecomponents of the topsheet into the system.

The nonwoven material is fed into the process at the place indicated bytheletter A. The first supply source 102 feeds a first material 24' usedto make the nonwoven fabric 24 into the system. The first material 24'can beany of those materials specified above as being suitable for usein or as the nonwoven fabric 24. The nonwoven material may be suppliedby any suitable supply source. The first supply source 102 couldinclude, but is not limited to any conventional means used to introducea material into a laminating process. The first supply source 102 couldbe, but is not limited to an unwind roll; a web or fabric producingmachine, such as a conventional carding machine, spunbonding machine; ora hopper for feedinga layer of loose fibers into the system.

In the process illustrated, the first supply source comprises a supplyroll102 which holds first material in the form of a nonwoven fabric web24'. The nonwoven fabric web 24' is preferably of a thin, softconstruction. Some preferred nonwoven fabrics are manufactured by theFiberweb Group under the trademarks "CELESTRA" and "HOLMESTRA".

The nonwoven fabric web 24' is preferably treated with an effectiveamount of surface active agent or surfactant. The surfactant providesthe nonwoven fabric's surface with greater polarizability than it wouldhave without the surfactant being added. Higher surface polarity yieldshigher wettability. Suitable surfactants include a product knowncommercially as ATMER 645 manufactured by ICI Specialty Chemicals.

The nonwoven fabric 24 may be treated with a surfactant prior to orduring the time it is manufactured. For example, it may be treated afterit is unwound from supply roll 102, or at any other time during theprocess described herein. The surfactant may be applied to eithersurface of the nonwoven fabric. This may be done by any knowntechniques, such as by spraying, by padding, or by the use of transferrolls. The surfactant can alternatively (or additionally) beincorporated into the nonwoven fabric such as between or within thefibers of the nonwoven fabric. Preferably, the nonwoven fabric istreated with a surfactant prior to the time it is supplied in thepresent process.

The thermoplastic material is fed into the process at the placeindicated B. The second supply source 104 feeds a second material 26'used to make the thermoplastic film 26 into the system. The secondmaterial 26' can be any of those materials specified above as beingsuitable for use in makingthe thermoplastic film 26. The thermoplasticmaterial is supplied by any suitable supply source 104. Thus, the secondsupply source could be any conventional means used to introduce a filminto a process. The second supply source 104 could be, but is notlimited to an unwind roll, a film producing machine, or a supply ofresin pellets from which the film is to be made. In the embodiment ofthe process illustrated, the second supply source is a die 104 in whichthermoplastic material is extruded and from which the thermoplasticmaterial flows.

The apertured plastic film 26 should also be treated with an effectiveamount of a surfactant. Treating the film with a surfactant isparticularly helpful in eliminating a prior problem of liquids passingthrough the nonwoven material, and collecting at the interface betweenthenonwoven material and the apertured film and then passing backthrough the nonwoven to contact the wearer's skin. The surfactant, thus,enhances the permeability completely through the topsheet 12.

The apertured plastic film 26 may be treated with the surfactant in anyof the general manners specified above (that are not inherently limitedto use with fibrous materials). Preferably, a small amount of surfactantis compounded into the resin pellets from which the film 26 is made. Thesurfactant can be compounded into polyolefin resin pellets such aspolyethylene resin pellets. After processing, the surfactant chemicaladditive exudes to the film surface. Such exudation is due to theinsolubility of the additive in the polyolefin at normal temperatures.During extrusion, the molten amorphous resin mass is quenched to asemi-crystalline web. As the ordered crystalline structure forms, theamorphous volume decreases. Since the additive molecules areincompatible in the crystalline structure and insoluble in the coolingamorphous region, they are squeezed or caused to migrate to the surfaceof the polyolefin.

The surfactant can be the same product referred to above knowncommerciallyas ATMER 645. The amount of the surfactant added should bean amount sufficient to render the desired fluid transport through thetopsheet 12 (after the corona discharge treatment described below). Whena surfactant treated nonwoven fabric, is used, the amount of surfactantis preferably from about 0.5 to about 1%, by weight, of the surfactantin relation to the thermoplastic material. If a non-treated nonwovenfabric is used, fromabout 2 to about 5% surfactant, by weight, inrelation to the thermoplasticmaterial should be used. It is believedthat the excess surfactant may migrate into the nonwoven fabric.

The die 104 supplies the thermoplastic material as a hot film 26' whichmoves along a predetermined path. In the present embodiment, a rotarycylindrical vacuum drum 126 is located along the predetermined path. Thenonwoven fabric web 24' is moved past an application roller 128 so thatitcomes in contact with the hot film 26'. The nonwoven fabric web 24'travelswith the hot film 26' along the side of the drum 126. The film26' is applied to the drum 126 where the nonwoven fabric web 24' isbonded to thehot film 26' by vacuum lamination to form a composite web12'.

The three-dimensional apertures are formed by placing a perforatedthree-dimensional forming element or screen on the drum 126. As the film26' is moved along the drum, an air pressure differential is appliedacross the film 26' toward a portion of the screen sufficient to distortthe film into the perforations of the forming element. The pressuredifferential thus created causes a forming and rupture of the film26'resulting in three-dimensional apertures. A process that can be usedtocreate three-dimensional apertures in plastic film is described indetail in U.S. Pat. Nos. 4,351,784, 4,456,570 and 4,535,020.

The composite web 12' passes between nip rollers 134 and 136 past aroller 138 to a corona treating roller 140. Although the chemicallytreated composite web 12' is more polar than an untreated web, coronadischarge treatment of the web 12' provides the desired maximumwettability. The corona treating roller 140 is usually covered with asuitable dielectric material such as epoxy, fluorinated polyethylene("TELFON"), chlorinated polyethylene ("HYPA-LON"), or polyester("MYLAR"). The electrode or coronabar 142 is suspended parallel to thecorona treating roller 140 at about 16mm above the roll. The corona bar142 is energized by a transformer and corona treating power source 144.The above described corona discharge treatment is described in detail inU.S. Pat. Nos. 4,351,784, 4,456,570 and 4,535,020. This completes theformation of the topsheet material 12.

The finished topsheet material 12 continues past a second tension roller146 to a slitter 148 where it is slit. The topsheet material 12 thenproceeds past rollers 150 and 152 to winder 154.

In alternative embodiments of the process of making the topsheet 12, thenonwoven material 24 and the film 26 can be secured in other manners.Typically, in these other processes the nonwoven material 24' is notapplied to the film until after the film is cooled. In one alternativeprocess, adhesives can be used to bond the nonwoven material 24 and thefilm 26 at their faces. In an adhesive bonding process, adhesive can beapplied by any suitable commercial adhesive supply device. The adhesivescan be applied using any suitable process. For example, the componentsmaybe separately manufactured and pre-coated with a pressure-sensitiveadhesive, and thereafter secured in a subsequent process. In anotherexample, adhesive could be applied to the nonwoven fabric 24 and thefilm 26 in a process similar to that shown in FIG. 9, and these twocomponents could be pressed together and bonded when they pass throughthe nip between nip rollers 134 and 136. Such adhesive bonding processescould, alternatively, be conducted without the application of pressure.In other embodiments, one of the rollers 134 or 136 could be providedwith a pattern and the other could serve as an anvil roller, and the twocomponents could be bonded together in the presence of heat and/orpressure. In still other embodiments, the rollers 134 or 136 could bereplaced by a commercially available ultrasonic welding device.

It is believed that the absorbent article 10 exhibits good strikethroughtimes and rewet values. Strikethrough time is a measure of the timeliquidtakes to penetrate through the topsheet 12. Rapid penetration ofthe topsheet 12 (i.e., low strikethrough time) is important to reducethe possibility of liquid running over the surface of topsheet 12.Strikethrough may be determined using any suitable procedure. Theshorter the strikethrough time, the better the strikethroughcharacteristics of the topsheet 12. The rewet value is a measure of theamount of liquid which flows from the absorbent core 16 to the outersurface of the topsheet 12. Large quantities of liquid on the outersurface of the topsheet 12 (i.e. high rewet values) are undesirablebecause they lead to the discomfort of the wearer of the disposableabsorbent article. The rewet value of an absorbent article may bedetermined using any suitable procedure. Suitable procedures formeasuring strikethrough and rewet are described in U.S. Pat. No.4,324,247 issued to Aziz. In an alternative version of the testsdescribed in the Aziz patent, however, the rewet value is determined bysubjecting the test sample to a pressure of about 1psi.

The nonwoven fabric and surfactant-treated apertured film topsheetprovidesan article that has aesthetic qualities superior to that of theplastic film alone and functional properties superior to that of thenonwoven fabric alone. The nonwoven fabric provides a skin contact layerthat is soft and aesthetically pleasing. When the film layer isthree-dimensional and apertured, the film layer provides transport offluids through the film and to an absorbent core while providing abarrier to fluid escape from the core that is difficult with a nonwovenfabric alone.

It will be understood by those skilled in the art that the invention hasbeen described with reference to an exemplary preferred embodiment andthat variations and modifications can be effected in the describedembodiment without departing from the scope and spirit of the invention.

What is claimed is:
 1. A liquid pervious topsheet for an absorbentarticle, said topsheet comprising a fibrous nonwoven material and anapertured plastic film placed together so that at least a portion of thefibers of said nonwoven material are embedded in some portion of saidfilm, wherein said film is treated with a surfactant to enhance theoverall permeability of said topsheet.
 2. The topsheet of claim 1wherein said film is comprised of a thermoplastic resinous material andsaid surfactant was mixed with said thermoplastic resinous material andincorporated into said film.
 3. The topsheet of claim 1 wherein saidnonwoven material is also treated with a surfactant.
 4. An absorbentarticle having a body-facing side, said absorbent article comprising:aliquid pervious topsheet, said topsheet comprising a fibrous nonwovenmaterial that forms the body-facing side of said absorbent article, andan apertured plastic film that underlies said nonwoven material, whereinat least a portion of the fibers of said nonwoven material are embeddedin some portion of said film and said film is treated with a surfactantto enhance the overall permeability of said topsheet; a liquidimpervious backsheet joined to said topsheet; and an absorbent corepositioned between said topsheet and said backsheet.
 5. The absorbentarticle of claim 4 wherein said film is comprised of a thermoplasticresinous material and said surfactant was mixed with said thermoplasticresinous material and incorporated into said film.
 6. A liquid pervioustopsheet for an absorbent article having a body-facing side, saidtopsheet comprising a fibrous nonwoven material and an apertured,thermoplastic film placed together in a face-to-face relationship sothat said nonwoven material forms the body-facing side of the absorbentarticle, and said film underlies said nonwoven material such that atleast a portion of the fibers of said nonwoven material are embedded insome portion of said film, wherein said film is comprised of a liquidimpervious thermoplastic resinous material which is treated with asurfactant to enhance the overall permeability of said topsheet, andsaid film has a thickness of from about 0.001 to 0.002 inches and isprovided with tapered capillaries in the form of frustums of cones thatdefine apertures, said tapered capillaries each having a base openingadjacent said nonwoven material and an oppositely disposed apex opening,an angle of taper of from about 10° to about 60° , a base openingdimension of from about 0.006 to about 0.250 inch, and an apex openingdimension of from about 0.004 to about 0.100 inch.
 7. A composite liquidpervious topsheet for an absorbent article having a body-facing side,said topsheet comprising:a nonwoven material comprising a plurality offibers, said nonwoven material having a body-facing side and agarment-facing side, said fibers comprising thermally bondedpolypropylene fibers, said nonwoven material having a basis weight fromabout 8 g/sq. m to about 12 g/sq. m; and a three-dimensional plasticfilm having a body-facing side and a garment-facing side and comprisedof a liquid impervious thermoplastic resinous material, said film beingprovided with a plurality of apertures and having a surfactant thereinto enhance the overall permeability of said topsheet; wherein: saidnonwoven material and said film are arranged so that said body-facingside of said nonwoven material is disposed above said body-facing sideof said film, and said garment-facing side of said nonwoven materiallies between said body-facing side of said film and said garment-facingside of said film.